Tufted laminate web

ABSTRACT

An absorbent article having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The topsheet has a first side and a second side, the first side being a body-facing side. The topsheet defines a CD-MD plane and includes a fibrous nonwoven web and tufts, the tufts having fibers of the fibrous nonwoven web. The topsheet further includes first, second and third zones, each zone being characterized in a Z-direction by the zone fiber orientation, wherein the first and third zones are displaced relative to each other and each include fibers having portions orientated substantially parallel to said CD-MD plane of the topsheet. The second zone is intermediate and adjacent to the first and third zones, the second zone including substantially reoriented fibers that are substantially vertically oriented with respect to the CD-MD plane of said topsheet.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.10/737,307, filed Dec. 16, 2003, which is a continuation-in-part of U.S.application Ser. No. 10/610,299; filed Jun. 30, 2003, now abandoned, andwhich is a continuation-in-part of U.S. application Ser. No. 10/435,996,now abandoned, which is a continuation-in-part of U.S. application Ser.No. 10/324,661, filed Dec. 20, 2002, now abandoned.

FIELD OF INVENTION

This invention relates to body facing layers of disposable absorbentarticles such as sanitary napkins. In particular, this invention relatesto topsheets having improved fluid handling properties.

BACKGROUND OF THE INVENTION

Disposable absorbent articles such as disposable diapers, incontinenceproducts, catamenial products and the like are widely used, and mucheffort has been made to improve the effectiveness and functionality ofthese articles. In general such articles have a fluid permeablebody-facing layer, often referred to as a topsheet, a fluid impermeablegarment-facing layer, often referred to as a backsheet, and an absorbentcore sandwiched between the topsheet and the backsheet. Othercomponents, such as acquisition layers, secondary topsheets, andadhesive fasteners are also well known in the art.

Conventional body-facing layers, i.e., topsheets, used in disposableabsorbent typically exhibit a tradeoff between improved acquisition ofgushes of fluid and improved dryness. For example, topsheets can be maderelatively hydrophilic to quickly wet out and acquire gushes of fluid,but this same relative hydrophilicity causes the topsheet to feel wetnext to the wearer's skin, i.e., dryness is compromised. Variousmaterial and component structures have been proposed in the past toprovide for either improved gush acquisition or improved rewet, but theproperties have remained linked, one being inversely proportional to theother.

It is known that providing for a certain amount of compression-resistantthickness, or caliper, in a topsheet aids in reducing rewet. Forexample, three-dimensional formed film topsheets such as those known asDRI-WEAVE® topsheets on ALWAYS® sanitary napkins marketed by The Procter& Gamble Co. are known to provide for low rewet, i.e., better dryness,compared to typical nonwoven topsheets. However, some consumers expressa dislike for polymer film topsheets and prefer topsheets made ofnonwoven materials.

Furthermore, known topsheets typically are not designed specifically forabsorption of high viscosity fluids such as runny bowel movements, woundexudates, blood, and menses. As a result, typical topsheets can leak,stain, and contribute to poor skin health due to prolonged contact withthe wearer's skin.

Accordingly, there is a need for an improved topsheet for a disposableabsorbent article capable of providing for high gush acquisition ratesand yet also providing for improved dryness.

Additionally, there is a need an improved topsheet for a disposableabsorbent article capable of providing for high gush acquisition ratesand yet also providing for improved dryness that is comfortable to thewearer.

Finally, there is a need for a method of relatively inexpensively makinga topsheet for a disposable absorbent article capable of providing forhigh gush acquisition rates and yet also providing for improved dryness.

SUMMARY OF THE INVENTION

An absorbent article having a topsheet, a backsheet, and an absorbentcore disposed between the topsheet and the backsheet. The topsheet has afirst side and a second side, the first side being a body-facing side.The topsheet defines a CD-MD plane and includes a fibrous nonwoven weband tufts, the tufts having fibers of the fibrous nonwoven web. Thetopsheet further includes first, second and third zones, each zone beingcharacterized in a Z-direction by the zone fiber orientation, whereinthe first and third zones are displaced relative to each other and eachinclude fibers having portions orientated substantially parallel to saidCD-MD plane of the topsheet. The second zone is intermediate andadjacent to the first and third zones, the second zone includingsubstantially reoriented fibers that are substantially verticallyoriented with respect to the CD-MD plane of said topsheet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a web suitable for use in an article ofthe present invention.

FIG. 2 is an enlarged view of a portion of the web shown in FIG. 1.

FIG. 3 is a cross-sectional view of section 3-3 of FIG. 2.

FIG. 4 is a plan view of a portion of the web as indicated by 4-4 inFIG. 3.

FIG. 5 is a perspective view of an apparatus for forming the web for usein the present invention.

FIG. 6 is a cross-sectional depiction of a portion of the apparatusshown in FIG. 5.

FIG. 7 is a perspective view of a portion of the apparatus for formingone embodiment of a web suitable for use in an article of the presentinvention.

FIG. 8 is an enlarged perspective view of a portion of the apparatus forforming a web suitable for use in an article of the present invention.

FIG. 9 is an enlarged view of a portion of another embodiment of a websuitable for use in an article of the present invention.

FIG. 10 is an enlarged view of a portion of another embodiment of a websuitable for use in an article of the present invention.

FIG. 11 is a partial cut away plan view of a sanitary napkin of thepresent invention.

FIG. 12 is a partial cut away perspective view of a tampon of thepresent invention.

FIGS. 13-15 are photomicrographs of a webs suitable for use in anarticle of the present invention.

FIG. 16 is a graph of fluid acquisition and rewet data for articles madewith webs of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a laminate web 1 suitable for use in an article of thepresent invention, hereinafter referred to simply as web 1. Web 1comprises at least two layers. The layers are referred to herein asgenerally planar, two-dimensional precursor webs, such as firstprecursor web 20 and second precursor web 21. Either precursor web canbe a film, a nonwoven, or a woven web. Precursor webs 20 and 21 (and anyadditional webs) can be joined by adhesive, thermal bonding, ultrasonicbonding and the like, but are preferably joined without the use ofadhesive or other forms of bonding. As disclosed below, the constituentprecursor webs of web 1 can be joined by interlocking mechanicalengagement resulting from the formation of tufts 6.

Web 1 has a first side 3 and a second side 5, the term “sides” beingused in the common usage of generally planar two-dimensional webs, suchas paper and films that have two sides when in a generally flatcondition. Each precursor web 20 and 21 has a first surface 12 and 13,respectively, and a second surface 14 and 15, respectively (shown inFIG. 3). Web 1 has a machine direction (MD) and a cross machinedirection (CD) as is commonly known in the art of web manufacture.Although the present invention can be practiced with polymer films andwoven webs, in a preferred embodiment first precursor web 20 is anonwoven web comprised of substantially randomly oriented fibers. By“substantially randomly oriented” is meant that, due to processingconditions of the precursor web, there may be a higher amount of fibersoriented in the MD than the CD, or vice-versa. For example, inspunbonding and meltblowing processes continuous strands of fibers aredeposited on a support moving in the MD. Despite attempts to make theorientation of the fibers of the spunbond or meltblown nonwoven webtruly “random,” usually a slightly higher percentage of fibers areoriented in the MD as opposed to the CD. In a preferred embodiment,second precursor web 21 is a nonwoven web similar to the first precursorweb 20, or a polymer film, such as a polyethylene film. If desired, thefilm could be apertured.

In one embodiment, first side 3 of web 1 is defined by exposed portionsof the first surface 13 of second precursor web 21 and at least one, butpreferably a plurality of, discrete tufts 6 which are integralextensions of the fibers of a nonwoven first precursor web 20. Each tuft6 can comprise a plurality of looped, aligned fibers 8 extending throughsecond precursor web 21 and outwardly from the first surface 13 thereof.In another embodiment each tuft 6 can comprise a plurality of non-loopedfibers 18 (as shown in FIG. 3) that extend outwardly from the firstsurface 13. In another embodiment, each tuft 6 can comprise a pluralityof fibers which are integral extensions of the fibers of both a nonwovenfirst precursor web 20 and a nonwoven second precursor web 21.

As used herein, the term “nonwoven web” refers to a web having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which do nottypically have randomly oriented fibers. Nonwoven webs or fabrics havebeen formed from many processes, such as, for example, meltblowingprocesses, spunbonding processes, spunlacing processes, hydroentangling,airlaying, and bonded carded web processes, including carded thermalbonding. The basis weight of nonwoven fabrics is usually expressed ingrams per square meter (gsm). The basis weight of the laminate web isthe combined basis weight of the constituent layers and any other addedcomponents. Fiber diameters are usually expressed in microns; fiber sizecan also be expressed in denier, which is a unit of weight per length offiber. The basis weight of laminate webs suitable for use in an articleof the present invention can range from 10 gsm to 100 gsm, depending onthe ultimate use of the web 1.

The constituent fibers of nonwoven precursor webs 20 and/or 21 can bepolymer fibers as known in the art. The fibers can be monocomponent,bicomponent, and/or biconstituent, non-round (e.g., capillary channelfibers), and can have major cross-sectional dimensions (e.g., diameterfor round fibers) ranging from 0.1-500 microns. The constituent fibersof the nonwoven precursor webs may also be a mixture of different fibertypes, differing in such features as chemistry (e.g. PE and PP),components (mono-and bi-), shape (i.e. capillary channel and round) andthe like. The constituent fibers can range from about 0.1 denier toabout 100 denier.

As used herein, “spunbond fibers” refers to small diameter fibers whichare formed by extruding molten thermoplastic material as filaments froma plurality of fine, usually circular capillaries of a spinneret withthe diameter of the extruded filaments then being rapidly reduced.Spunbond fibers are generally not tacky when they are deposited on acollecting surface. Spunbond fibers are generally continuous and haveaverage diameters (from a sample of at least 10) larger than 7 microns,and more particularly, between about 10 and 40 microns.

As used herein, the term “meltblowing” refers to a process in whichfibers are formed by extruding a molten thermoplastic material through aplurality of fine, usually circular, die capillaries as molten threadsor filaments into converging high velocity, usually heated, gas (forexample air) streams which attenuate the filaments of moltenthermoplastic material to reduce their diameter, which may be tomicrofiber diameter. Thereafter, the meltblown fibers are carried by thehigh velocity gas stream and are deposited on a collecting surface,often while still tacky, to form a web of randomly dispersed meltblownfibers. Meltblown fibers are microfibers which may be continuous ordiscontinuous and are generally smaller than 10 microns in averagediameter.

As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as for example, block, graft,random and alternating copolymers, terpolymers, etc., and blends andmodifications thereof. In addition, unless otherwise specificallylimited, the term “polymer” includes all possible geometricconfigurations of the material. The configurations include, but are notlimited to, isotactic, atactic, syndiotactic, and random symmetries.

As used herein, the term “monocomponent” fiber refers to a fiber formedfrom one or more extruders using only one polymer. This is not meant toexclude fibers formed from one polymer to which small amounts ofadditives have been added for coloration, antistatic properties,lubrication, hydrophilicity, etc. These additives, for example titaniumdioxide for coloration, are generally present in an amount less thanabout 5 weight percent and more typically about 2 weight percent.

As used herein, the term “bicomponent fibers” refers to fibers whichhave been formed from at least two different polymers extruded fromseparate extruders but spun together to form one fiber. Bicomponentfibers are also sometimes referred to as conjugate fibers ormulticomponent fibers. The polymers are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thebicomponent fibers and extend continuously along the length of thebicomponent fibers. The configuration of such a bicomponent fiber maybe, for example, a sheath/core arrangement wherein one polymer issurrounded by another, or may be a side-by-side arrangement, a piearrangement, or an “islands-in-the-sea” arrangement.

As used herein, the term “biconstituent fibers” refers to fibers whichhave been formed from at least two polymers extruded from the sameextruder as a blend. Biconstituent fibers do not have the variouspolymer components arranged in relatively constantly positioned distinctzones across the crosssectional area of the fiber and the variouspolymers are usually not continuous along the entire length of thefiber, instead usually forming fibrils which start and end at random.Biconstituent fibers are sometimes also referred to as multiconstituentfibers.

As used herein, the term “non-round fibers” describes fibers having anon-round cross-section, and include “shaped fibers” and “capillarychannel fibers” as are known in the art. Such fibers can be solid orhollow, and they can be tri-lobal, delta-shaped, and are preferablyfibers having capillary channels on their outer surfaces. The capillarychannels can be of various cross-sectional shapes such as “U-shaped”,“H-shaped”, “C-shaped” and “V-shaped”. One preferred capillary channelfiber is T-401, designated as 4DG fiber available from Fiber InnovationTechnologies, Johnson City, Tenn. T-401 fiber is a polyethyleneterephthalate (PET).

As used herein, the term “integral” as in “integral extension” when usedof the tufts 6 refers to fibers of the tufts 6 having originated fromthe fibers of the precursor webs 20 and/or 21. Therefore, the loopedfibers 8 and non-looped fibers 18 of tufts 6, can be plasticallydeformed and extended fibers of the first precursor web 20, and are,therefore, integral with first precursor web 20. Similarly, forembodiments wherein second precursor web 21 is a nonwoven comprisingsimilarly extensible fibers, the fibers of second precursor web 21 cancontribute to tufts 6. As used herein, “integral” is to be distinguishedfrom fibers introduced to or added to a separate precursor web for thepurpose of making tufts, as is commonly done in conventional carpetmaking, for example.

The number, spacing, and dimensions of tufts 6 can be varied to givevarying texture to first side 3 of web 1. For example, if tufts 6 aresufficiently closely spaced the first side 3 of web 1 can have a terrycloth-like feel. Alternatively, tufts 6 can be arranged in patterns suchas lines or filled shapes to create portions of a laminate web havinggreater texture, softness, bulk, absorbency or visual design appeal. Forexample, when tufts 6 are arranged in a pattern of a line or lines, thetufts can have the appearance of stitching. Tufts 6 can also be arrangedto form specific shapes, such as designs, words or logos. Likewise, thesize dimensions, such as the height, length and width of individualtufts 6 can be varied. Single tufts can be as long as about 3 cm inlength and can be made alone or dispersed among tufts of various sizes.

First precursor web 20 can be a fibrous woven or nonwoven web comprisingfibers having sufficient elongation properties to have portions formedinto tufts 6. As described more fully below, tufts are formed by urgingfibers out-of-plane in the Z-direction at discrete, localized, portionsof first precursor web 20. The urging out-of-plane can be due to fiberdisplacement, i.e., the fiber is able to move relative to other fibersand be “pulled,” so to speak, out-of-plane. More often, however, formost nonwoven first precursor webs 20, the urging out-of-plane is due tothe fibers of tufts 6 having been at least partially plasticallystretched and permanently deformed to form tufts 6. Therefore, in oneembodiment, depending on the desired height of tufts 6, the constituentfibers of a nonwoven first precursor webs 20 can exhibit an elongationto break of at least about 5%, more preferably at least about 10%, morepreferably at least about 25%, more preferably at least about 50%, andmore preferably at least about 100%. Elongation to break can bedetermined by simple tensile testing, such as by use of Instron tensiletesting equipment, and can generally be found on material data sheetsfrom suppliers of such fibers or webs.

It can be appreciated that a suitable nonwoven first precursor web 20should comprise fibers capable of experiencing sufficient plasticdeformation and tensile elongation, or are capable of sufficient fibermobility, such that looped fibers 8 are formed. However, it isrecognized that a certain percentage of fibers urged out of the plane ofthe first surface 12 of first precursor web 20 will not form a loop, butinstead will break and form loose ends. Such fibers are referred toherein as “loose” fibers or “loose fiber ends” 18 as shown in FIG. 3.Loose fiber ends 18 are not necessarily undesirable for the presentinvention, and in some embodiments, most or all of the fibers of tufts 6can be loose fiber ends 18. Loose fiber ends 18 can also be the resultof forming tufts 6 from nonwoven webs consisting of, or containing, cutstaple fibers. In such a case, some number of the staple fiber ends mayprotrude into the tuft 6, depending upon such things as the number ofstaple fibers in the web, the staple fiber cut length, and the height ofthe tufts.

First precursor web 20 can be a fibrous woven or nonwoven web comprisingelastic or elastomeric fibers. Elastic or elastomeric fibers can bestretched at least about 50% and return to within 10% of their originaldimension. Tufts 6 can be formed from elastic fibers if the fibers aresimply displaced due to the mobility of the fiber within the nonwoven,or if the fibers are stretched beyond their elastic limit and areplastically deformed.

For use as a topsheet in the present invention, first precursor web 20can be relatively hydrophilic compared to second precursor web 21. In apreferred embodiment first precursor web 20 is also hydrophilic comparedto the skin of the wearer of an article of the present invention. Inthis manner, fluid in contact with the topsheet of the present inventioncan be wetted out onto the fibers of first precursor web, conducted bycapillarity action through the openings 4 of the second precursor web 21to underlying components of an article of the present invention. Whileactual measures of hydrophilicity or hydrophobicity are not consideredto be critical (only relative hydrophilicity/hydrophobicity between thefirst precursor web 20 and the second precursor web 21), in general,first precursor web 20 can be considered hydrophilic if it exhibits acontact angle with water of less than about 70 degrees. If firstprecursor web is not naturally hydrophilic (i.e., the polymer propertiesare not hydrophilic), it can be rendered hydrophilic by methods known inthe art, for example, by application of a surfactant to the fibersand/or the web.

Second precursor web 21 can be virtually any web material, the onlyrequirement being that it be less hydrophilic, and even hydrophobicrelative to first precursor web 20, and that it have sufficientintegrity to be formed into a laminate by the process described below.In one embodiment, second precursor web can be a film or a nonwoven webhaving sufficiently less elongation properties relative to firstprecursor web 20, such that upon experiencing the strain of fibers fromfirst precursor web 20 being urged out-of-plane in the direction ofsecond precursor web 21, second precursor web 21 will rupture, e.g., bytearing due to extensional failure, such that portions of firstprecursor web 20 can extend through, (i.e., “punch through” so tospeak), second precursor web 21 to form tufts 6 on first side 3 of web1, as shown in FIG. 1. In one embodiment second precursor web 21 is apolymer film. In one embodiment second precursor web 21 is a nonwovenweb.

A representative tuft 6 for the embodiment of web 1 shown in FIG. 1 isshown in a further enlarged view in FIG. 2. As shown, tuft 6 comprises aplurality of looped fibers 8 that are substantially aligned such thattuft 6 has a distinct linear orientation and a longitudinal axis L. Tuft6 also have a transverse axis T generally orthogonal to longitudinalaxis L in the MD-CD plane. In the embodiment shown in FIGS. 1 and 2,longitudinal axis L is parallel to the MD. In one embodiment, all thespaced apart tufts 6 have generally parallel longitudinal axes L. Thenumber of tufts 6 per unit area of web 1, i.e., the area density of tuft6, can be varied from 1 tuft per unit area, e.g., square centimeter toas high as 100 tufts per square centimeter. There can be at least 10, orat least 20 tufts 6 per square centimeter, depending on the end use. Ingeneral, the area density need not be uniform across the entire area ofweb 1, but tufts 6 can be only in certain regions of web 1, such as inregions having predetermined shapes, such as lines, stripes, bands,circles, and the like.

As can be appreciated by the description herein, in many embodiments ofweb 1 openings 4 will have a distinct linear orientation and alongitudinal axis, which is oriented parallel to the longitudinal axis Lof its corresponding tuft 6. Likewise, openings 4 will also have atransverse axis generally orthogonal to longitudinal axis in the MD-CDplane.

As shown in FIGS. 1-4, tufts 6 extend through openings 4 in secondprecursor web 21. Openings 4 are formed by locally rupturing secondprecursor web 21 by the process described in detail below, or by urgingfibers of second precursor web 21 out of plane in like manner as fibers8. Rupture may involve a simple splitting open of second precursor web21, such that opening 4 remains a simple two-dimensional aperture.However, for some materials, such as polymer films, portions of secondprecursor web 21 can be deflected or urged out-of-plane (i.e., the planeof second precursor web 21) to form flap-like structures, referred toherein as flap, or flaps, 7. The form and structure of flaps 7 is highlydependent upon the material properties of second precursor web 21. Flaps7 can have the general structure of one or more flaps, as shown in FIGS.1 and 2. In other embodiments, flap 7 can have a more volcano-likestructure, as if the tuft 6 is erupting from the flap 7.

In one embodiment flaps 7 do not contribute significantly to thematerial of tufts 6, and particularly do not contribute significantly tothe tactile quality of tufts 6. In one embodiment, therefore, thelaminate web 1 comprises at least two layers (i.e., precursor webs 20and 21), but at least one of the layers (i.e., precursor web 21 in FIGS.1-4) does not significantly affect on the tactile qualities of tufts 6.

In one embodiment, flaps 7 may extend out of plane significantly, evenbeing as high, so to speak, as the tufts 6 themselves. In thisembodiment flaps 7 can cause the tufts 6 to be more resilient and lesssusceptible to flattening due to compressive or bending forces. In oneembodiment, therefore, the laminate web 1 comprises at least two layers(i.e., precursor webs 20 and 21), and both layers affect the tactilequalities of tufts 6.

Tufts 6 can be, in a sense, “punched through” second precursor web 21and can be “locked” in place by frictional engagement with openings 4.In some embodiments, for example, the lateral width of opening 4 (i.e.,the dimension measured parallel to its transverse axis) can be less thanthe maximum width of the tooth that formed the opening (per the processdescribed below). This indicates a certain amount of recovery at theopening that tends to constrain tuft 6 from pulling back out throughopening 4. The frictional engagement of the tufts and openings providesfor a laminate web structure having permanent tufting on one side thatcan be formed without adhesives or thermal bonding.

Tufts 6 can be spaced sufficiently closely so as to effectively coverfirst side 3 of web 1. In such an embodiment, both sides of web 1 appearto comprise nonwoven fibers integral with first precursor web 20, with adifference between the two sides 3 and 5 being a difference in surfacetexture. Therefore, in one embodiment, a topsheet of the presentinvention can be described as a laminate material of two or moreprecursor webs, wherein both sides of the laminate web are substantiallycovered by fibers from only one of the precursor webs. Specifically, atopsheet of the present invention can be described as comprising a firstrelatively hydrophobic component (i.e., second precursor web 21) and asecond relatively hydrophilic component (i.e., first precursor web 20)wherein the relatively hydrophilic component extends through therelatively hydrophobic component and is disposed on both sides (i.e.,sides 3 and 5) of said topsheet.

As shown in FIGS. 1-4, one characteristic of tufts 6 can be thepredominant directional alignment of the fibers 8 or 18. For example,looped, aligned fibers 8 can be described as having a significant ormajor vector component parallel to the Z-CD plane and the looped fibers8 have a substantially uniform alignment with respect to transverse axisT when viewed in plan view, such as in FIG. 4. By “looped” fibers 8 ismeant fibers 8 that are integral with and begin and end in firstprecursor web 20 and/or second precursor web 21 but extend outwardly inthe Z-direction from first side 3 of web 1. By “aligned” with respect tolooped fibers 8 of tufts 6 is meant that looped fibers 8 are allgenerally oriented such that, if viewed in plan view as in FIG. 4, eachof the looped fibers 8 has a significant vector component parallel tothe transverse axis T, and preferably a major vector component parallelto the transverse axis T. Although only fibers from first precursor web20 are shown in FIGS. 1-4, it is to be understood that this is becausein these FIGS. a film/nonwoven web 1 is depicted, in which theelongation properties of the web result in tensile failure to formopening 4 through which fibers 8 and/or 18 can protrude. It isunderstood that if a nonwoven/nonwoven web 1 were depicted, fibers fromeach of precursor webs 20 and 21 could form tufts 6, and, in such astructure, the tufts 6 could exhibit a substantially layered structure,the fibers of first precursor web 20 being generally internally-disposedin tufts 6.

In contrast, non-looped fibers 18 are integral with, but only begin infirst or second precursor webs 20 and/or 21 and have a free endextending outwardly in the Z-direction from first side 3 of web 1. Loosefibers 18 can also have a generally uniform alignment described ashaving a significant or major vector component parallel to the Z-CDplane.

For both looped fibers 8 and loose fibers 18, the alignment is acharacteristic of tufts 6 prior to any post-manufacture deformation dueto winding onto a roll, or compression in use in an article ofmanufacture. As used herein, a looped fiber 8 oriented at an angle ofgreater than 45 degrees from the longitudinal axis L when viewed in planview, as in FIG. 4, has a significant vector component parallel to thetransverse axis T. As used herein, a looped fiber 8 oriented at an angleof greater than 60 degrees from longitudinal axis L when viewed in planview, as in FIG. 4, has a major vector component parallel to thetransverse axis T. In a preferred embodiment, at least 50%, morepreferably at least 70%, and more preferably at least 90% of fibers 8 oftuft 6 have a significant, and more preferably, a major vector componentparallel to transverse axis T. Fiber orientation can be determined byuse of magnifying means if necessary, such as a microscope fitted with asuitable measurement scale. In general, for a non-linear segment offiber viewed in plan view, a straight-line approximation for bothlongitudinal axis L and the looped fibers 8 can be used for determiningthe angle of looped fibers 8 from longitudinal axis L. For example, asshown in FIG. 4, one fiber 8 a is shown emphasized by a heavy line, andit's linear approximation 8b is shown as a dashed line. This fiber makesan angle of approximately 80 degrees with the longitudinal axis(measured counterclockwise from L).

The orientation of looped fibers 8 in the tufts 6 is to be contrastedwith the fiber composition and orientation for first or second precursorwebs 20 and 21 (if a nonwoven web is used for second precursor web 21),which, for nonwoven webs is best described as having a substantiallyrandomly-oriented fiber alignment. In a woven web embodiment, theorientation of the looped fibers 8 in tufts 6 could be the same asdescribed above, but the fibers of woven precursor webs would have theorientation associated with the particular weaving process used to makethe web, e.g., a square weave pattern.

In the embodiment shown in FIG. 1 the longitudinal axes L of tufts 6 aregenerally aligned in the MD. Tufts 6 and, therefore, longitudinal axesL, can, in principle, be aligned in any orientation with respect to theMD or CD. Therefore, in general, it can be said that for each tuft 6,the looped aligned fibers 8 are aligned generally orthogonal to thelongitudinal axis L such that they have a significant vector componentparallel to transverse axis T, and more preferably a major vectorcomponent parallel to transverse axis T.

In some embodiments, due to the preferred method of forming tufts 6, asdescribed below, another characteristic of tufts 6 comprisingpredominantly looped, aligned fibers 8, can be their generally openstructure characterized by open void area 10 defined interiorly of tufts6. By “void area” is not meant an area completely free of any fibers;the term is meant as a general description of the general appearance oftufts 6. Therefore, it may be that in some tufts 6 a loose fiber 18 or aplurality of loose fibers 18 may be present in the void area 10. By“open” void area is meant that the two longitudinal ends of tuft 6 aregenerally open and free of fibers, such that tuft 6 can form somethinglike a “tunnel” structure in an uncompressed state, as shown in FIG. 3.

Void area 10 is believed to contribute to the surprising fluid handlingproperties of web 1 when used as a topsheet on a disposable absorbentarticle, as described more fully below. By having generally open endstufts 6 provide for “lateral entry” of fluids, particularly viscousfluids having solid components, such as menses.

One way of describing the structure of web 1 is with respect to thethree-dimensional fiber orientation in the Z-direction, as shown in FIG.3, for example. As shown in FIG. 3, at least three “zones” can beidentified, with each zone being identified with a portion of web 1 inthe Z-direction. A lowermost portion of web 1 designated as zone 1, Z1,extend generally from lower surface 14 of first precursor web 1 to theupper surface 13 of second precursor web 21 and comprises substantiallynon-reoriented fibers of the first and second precursor webs. The fibersof Z1 are substantially horizontally-oriented with respect to the CD-MDplane with very little Z-directionality. Zone 2, Z2, extends generallyfrom the upper surface 13 of second precursor web 21 to the interiorlimit of void area 10 and comprises substantially reoriented fibers thatare substantially vertically-oriented with respect to the CD-MD plane,that is, fibers in zone Z2 are oriented predominantly in the Z directionand have very little CD or MD directionality. In Zone 3, Z3, whichcomprises the fibers of distal portion 31 of tuft 6, fibers are againoriented generally horizontally with respect to the CD-MD plane.Therefore, in one embodiment, web 1 can be described structurally as anonwoven web, which in a generally flat condition defining a plane ofthe web, the web comprising tufted regions, the tufted regions havingthree zones, each zone characterized by the zone fiber orientation,wherein the first and third zones comprise fibers having a firstorientation substantially parallel to the plane of the web, and a secondzone intermediate to and joining the first and third zones, the secondzone comprising fibers having second orientation, the second orientationbeing substantially orthogonal to the first plane of the web, that is,having substantially no portions oriented substantially parallel to thefirst plane of the web.

In one preferred embodiment of web 1 for use as a topsheet on adisposable article, both precursor webs 20 and 21 are nonwoven webs,with second precursor web 21 being relatively hydrophobic with respectto first precursor web 20 (and, preferably, the skin or hair of thewearer), and both contribute fibers to tufts 6 in a relatively layeredmanner. In such a topsheet, as described more fully below with respectto FIG. 10, a large portion, if not all, of the fibers in closestproximity to the skin of the wearer can be relatively hydrophobic, suchthat relatively dry fibers can be in closest proximity to the skin ofthe wearer. By having lateral entry to the voids 10 of tufts 6, however,fluid can contact relatively hydrophilic fibers of first precursor web20 and be wicked through web 1 to components, such as a secondarytopsheet or absorbent core in the absorbent article.

As a consequence of a preferred method of making web 1, the second side5 of web 1 exhibits discontinuities 16 characterized by a generallylinear indentation defined by formerly random fibers of the secondsurface 14 of first precursor web 20 having been urged directionally(i.e., in the “Z-direction” generally orthogonal to the MD-CD plane asshown in FIGS. 1 and 3) into tufts 6 by the teeth of the formingstructure, described in detail below. The abrupt change of orientationexhibited by the previously randomly-oriented fibers of first precursorweb 20 defines the discontinuity 16, which exhibits a linearity suchthat it can be described as having a longitudinal axis generallyparallel to longitudinal axis L of the tuft 6. Due to the nature of manynonwoven webs useful as first precursor webs 20, discontinuity 16 maynot be as distinctly noticeable as tufts 6. For this reason, thediscontinuities 16 on the second side 5 of web 1 can go unnoticed andmay be generally undetected unless web 1 is closely inspected. As such,the second side 5 of web 1 can have the look and feel of an un-tuftedfirst precursor web 20. Thus in some embodiments, web 1 can have thetextured look and feel of terry cloth on first side 3, and a relativelysmooth, soft look and feel on second side 5, both sides being comprisedof fibers from the same nonwoven web, i.e., the first precursor web 20.In other embodiments, discontinuities 16 can appear as apertures, andmay be apertures through web 1 via the ends of the tunnel-like tufts 6.

From the description of web 1 comprising at least a nonwoven firstprecursor web 20, it can be seen that the fibers 8 or 18 of tuft 6 canoriginate and extend from either the first surface 12 or the secondsurface 14 of first precursor web 20. Of course the fibers 8 or 18 oftuft 6 can also extend from the interior 28 of first precursor web 20.The fibers 8 or 18 of tufts 6 extend due to having been urged out of thegenerally two-dimensional plane of first precursor web 20 (i.e., urgedin the “Z-direction” as shown in FIG. 3). In general, the fibers 8 or 18of the tufts 6 comprise fibers that are integral with and extend fromthe fibers of the either precursor web 20 or 21.

Therefore, from the above description, it is understood that in oneembodiment web 1 can be described as being a laminate web formed byselective mechanical deformation of at least a first and secondprecursor webs, at least the first precursor web being a nonwoven web,the laminate web having a first side, the first side comprising thesecond precursor web and a plurality of discrete tufts, each of thediscrete tufts comprising a plurality of tufted fibers being integralextensions of at least the first precursor web and extending through thesecond precursor web; and a second side, the second side comprising thefirst precursor web.

The extension of fibers 8 or 18 can be accompanied by a generalreduction in fiber cross sectional dimension (e.g., diameter for roundfibers) due to plastic deformation of the fibers and Poisson's ratioeffects. Therefore, the aligned looped fibers 8 of tuft 6 can have anaverage fiber diameter less than the average fiber diameter of thefibers of first or second precursor webs 20 or 21. It is believed thatthis reduction in fiber diameter contributes to the perceived softnessof the first side 3 of web 1, a softness that can be comparable tocotton terry cloth, depending on the material properties of the firstprecursor web 20. It has been found that the reduction in fibercross-sectional dimension is greatest intermediate the base 17 and thedistal portion 3 of tuft 6. This is believed to be due to the preferredmethod of making, as disclosed more fully below. Briefly, it is believedthat portions of fibers at the base 5 and distal portion 3 of tufts 6are adjacent the tip of teeth 110 of roll 104, described more fullybelow, and are frictionally locked and immobile during processing. Thus,the intermediate portions of tufts 6 are more free to stretch, orelongate, and accordingly, can experience a corresponding fiber crosssectional dimension reduction.

Referring to FIG. 5 there is shown in an apparatus and method for makingweb 1. The apparatus 100 comprises a pair of intermeshing rolls 102 and104, each rotating about an axis A, the axes A being parallel in thesame plane. Roll 102 comprises a plurality of ridges 106 andcorresponding grooves 108 which extend unbroken about the entirecircumference of roll 102. Roll 104 is similar to roll 102, but ratherthan having ridges that extend unbroken about the entire circumference,roll 104 comprises a plurality of rows of circumferentially-extendingridges that have been modified to be rows of circumferentially-spacedteeth 110 that extend in spaced relationship about at least a portion ofroll 104. The individual rows of teeth 110 of roll 104 are separated bycorresponding grooves 112. In operation, rolls 102 and 104 intermeshsuch that the ridges 106 of roll 102 extend into the grooves 112 of roll104 and the teeth 110 of roll 104 extend into the grooves 108 of roll102. The intermeshing is shown in greater detail in the cross sectionalrepresentation of FIG. 6, discussed below. Both or either of rolls 102and 104 can be heated by means known in the art such as by using hot oilfilled rollers or electrically-heated rollers.

In FIG. 5, the apparatus 100 is shown in a preferred configurationhaving one patterned roll, e.g., roll 104, and one non-patterned groovedroll 102. However, in certain embodiments it may be preferable to usetwo patterned rolls 104 having either the same or differing patterns, inthe same or different corresponding regions of the respective rolls.Such an apparatus can produce webs with tufts 6 protruding from bothsides of the web 1.

The method of making a web 1 in a commercially-viable continuous processis depicted in FIG. 5. Web 1 is made by mechanically deforming precursorwebs, such as first and second precursor webs, 20 and 21 that can eachbe described as generally planar and two dimensional prior to processingby the apparatus shown in FIG. 5. By “planar” and “two dimensional” ismeant simply that the webs start the process in a generally flatcondition relative to the finished web 1 that has distinct,out-of-plane, Z-direction three-dimensionality due to the formation oftufts 6. “Planar” and “two-dimensional” are not meant to imply anyparticular flatness, smoothness or dimensionality.

The process and apparatus of the present invention is similar in manyrespects to a process described in U.S. Pat. No. 5,518,801 entitled “WebMaterials Exhibiting Elastic-Like Behavior” and referred to insubsequent patent literature as “SELF” webs, which stands for“Structural Elastic-like Film”. However, there are significantdifferences between the apparatus and process of the present inventionand the apparatus and process disclosed in the '801 patent, and thedifferences are apparent in the respective webs produced thereby. Asdescribed below, the teeth 110 of roll 104 have a specific geometryassociated with the leading and trailing edges that permit the teeth toessentially “punch” through the precursor webs 20, 21 as opposed to, inessence, deforming the web. In a two layer laminate web 1 the teeth 110urge fibers from precursor webs 20 and 21 out-of-plane by the teeth 110pushing the fibers 8 through to form tufts 6. Therefore, a web 1 canhave tufts 6 comprising loose fiber ends 18 and/or “tunnel-like” tufts 6of looped, aligned fibers 8 extending away from the surface 13 of side3, unlike the “tent-like” rib-like elements of SELF webs which each havecontinuous side walls associated therewith, i.e., a continuous“transition zone,” and which do not exhibit interpenetration of onelayer through another layer.

Precursor webs 20 and 21 are provided either directly from theirrespective web making processes or indirectly from supply rolls (neithershown) and moved in the machine direction to the nip 116 ofcounter-rotating intermeshing rolls 102 and 104. The precursor webs arepreferably held in a sufficient web tension so as to enter the nip 16 ina generally flattened condition by means well known in the art of webhandling. As each precursor web 20, 21 goes through the nip 116 theteeth 110 of roll 104 which are intermeshed with grooves 108 of roll 102simultaneously urge portions of precursor webs 20 and 21 out of theplane to form tufts 6. In one embodiment, teeth 110 in effect “push” or“punch” fibers of first precursor web 20 through second precursor web21. In another embodiment teeth 110 in effect “push” or “punch” fibersof both first and second precursor webs 20 and 21 out of plane to formtufts 6.

As the tip of teeth 110 push through first and second precursor webs 20,21 the portions of the fibers of first precursor web 20 (and, in someembodiments, second precursor web 21) that are oriented predominantly inthe CD across teeth 110 are urged by the teeth 110 out of the plane offirst precursor web 20. Fibers can be urged out of plane due to fibermobility, or they can be urged out of plane by being stretched and/orplastically deformed in the Z-direction. Portions of the precursor websurged out of plane by teeth 110 result in formation of tufts 6 on firstside 3 of web 1. Fibers of precursor webs 20 and 21 that arepredominantly oriented generally parallel to the longitudinal axis L,i.e., in the MD as shown in FIG. 1, are simply spread apart by teeth 110and remain substantially in their original, randomly-oriented condition.This is why the looped fibers 8 can exhibit the unique fiber orientationin embodiments such as the one shown in FIGS. 1-4, which is a highpercentage of fibers of each tuft 6 having a significant or major vectorcomponent parallel to the transverse axis T of tuft 6.

It can be appreciated by the forgoing description that when web 1 ismade by the apparatus and method of the present invention that theprecursor webs 20, 21 can possess differing material properties withrespect to the ability of the precursor webs to elongate before failure,e.g., failure due to tensile stresses. In one embodiment, a nonwovenfirst precursor web 20 can have greater fiber mobility and/or greaterfiber elongation characteristics relative to second precursor web 21,such that the fibers thereof can move or stretch sufficiently to formtufts 6 while the second precursor web 21 ruptures, i.e., does notstretch to the extent necessary to form tufts. In another embodiment,second precursor web 21 can have greater fiber mobility and/or greaterfiber elongation characteristics relative to first precursor web 20,such that both first and second precursor webs 20 and 21 form tufts 6.In another embodiment, second precursor web 21 can have greater fibermobility and/or greater fiber elongation characteristics relative tofirst precursor web 20, such that the fibers of second precursor web 21can move or stretch sufficiently to form tufts 6 while the firstprecursor web 20 ruptures, i.e., does not stretch to the extentnecessary to form tufts.

The degree to which the fibers of nonwoven precursor webs are able toextend out of plane without plastic deformation can depend upon thedegree of inter-fiber bonding of the precursor web. For example, if thefibers of a nonwoven precursor web are only very loosely entangled toeach other, they will be more able to slip by each other (i.e., to moverelative to adjacent fibers by reptation) and therefore be more easilyextended out of plane to form tufts. On the other hand, fibers of anonwoven precursor web that are more strongly bonded, for example byhigh levels of thermal point bonding, hydroentanglement, or the like,will more likely require greater degrees of plastic deformation inextended out-of-plane tufts. Therefore, in one embodiment, one precursorweb 20 or 21 can be a nonwoven web having relatively low inter-fiberbonding, and the other precursor web 20 or 21 can be a nonwoven webhaving relatively high inter-fiber bonding, such that the fibers of oneprecursor web can extend out of plane, while the fibers of the otherprecursor web cannot. Optionally, a precursor web 20 or 21 may have amoderate level of inter-fiber bonding which maximizes the combination offiber mobility which enables fibers to more easily extend out of theplane to form tufts and web stability which minimizes the collapsing ofthe tufts.

In one embodiment, for a given maximum strain (e.g., the strain imposedby teeth 110 of apparatus 100), it is beneficial that second precursorweb 21 actually fail under the tensile loading produced by the imposedstrain. That is, for the tufts 6 comprising only, or primarily, fibersfrom first precursor web 20 to be disposed on the first side 3 of web 1,second precursor web 21 must have sufficiently low fiber mobility (ifany) and/or relatively low elongation-to-break such that it locally(i.e., in the area of strain) fails in tension, thereby producingopenings 4 through which tufts 6 can extend.

In another embodiment it is beneficial that second precursor web 21deform or stretch in the region of induced strain, and does not fail,such that tuft 6 includes portions of second precursor web 21 result.

In one embodiment second precursor web 21 has an elongation to break inthe range of 1%-5%. While the actual required elongation to breakdepends on the strain to be induced to form web 1, it is recognized thatfor most embodiments, second precursor web 21 can exhibit a webelongation-to-break of 6%, 7%, 8%, 9%, 10%, or more. It is alsorecognized that actual elongation-to-break can depend on the strainrate, which, for the apparatus shown in FIG. 5 is a function of linespeed. Elongation to break of webs used in the present invention can bemeasured by means known in the art, such as by standard tensile testingmethods using standard tensile testing apparatuses, such as thosemanufactured by Instron, MTS, Thwing-Albert, and the like.

Relative to first precursor web 20, second precursor web 21 can havelower fiber mobility (if any) and/or lower elongation-to-break (i.e.,elongation-to-break of individual fibers, or, if a film,elongation-to-break of the film) such that, rather than extendingout-of-plane to the extent of the tufts 6, second precursor web 21 failsin tension under the strain produced by the formation of tufts 6, e.g.,by the teeth 110 of apparatus 100. In one embodiment, second precursorweb 21 exhibits sufficiently low elongation-to-break relative to firstprecursor web 20 such that flaps 7 of opening 4 only extend slightlyout-of-plane, if at all, relative to tufts 6. In general, forembodiments in which tufts 6 comprise primarily fibers from firstprecursor web 20, it is believed that second precursor web 21 shouldhave an elongation to break of at least 10% less than the firstprecursor web 20, preferably at least 30% less, more preferably at least50% less, and even more preferably at least about 100% less than that offirst precursor web 20. Relative elongation to break values of webs usedin the present invention can be measured by means known in the art, suchas by standard tensile testing methods using standard tensile testingapparatuses, such as those manufactured by Instron, MTS, Thwing-Albert,and the like.

In one embodiment second precursor web 21 can comprise substantially allMD-oriented fibers, e.g., tow fibers, such that there are substantiallyno fibers oriented in the CD. For such an embodiment of web 1 the fibersof second precursor web 21 can simply separate at the opening 4 throughwhich tufts 6 extend. In this embodiment, therefore, second precursorweb 21 need not have any minimum elongation to break, since failure orrupture of the material is not the mode of forming opening 4.

The number, spacing, and size of tufts 6 can be varied by changing thenumber, spacing, and size of teeth 110 and making correspondingdimensional changes as necessary to roll 104 and/or roll 102. Thisvariation, together with the variation possible in precursor webs 20, 21permits many varied webs 1 having varied fluid handling properties foruse in a disposable absorbent article. As described more fully below, aweb 1 comprising a nonwoven/film first precursor web/second precursorweb combination can also be used as a component in disposable absorbentarticles. However, a nonwoven/nonwoven precursor web/second precursorweb combination wherein fibers from both webs contribute to tufts 6 isalso suitable.

FIG. 6 shows in cross section a portion of the intermeshing rolls 102and 104 and ridges 106 and teeth 110. As shown teeth 110 have a toothheight TH (note that TH can also be applied to ridge height; in apreferred embodiment tooth height and ridge height are equal), and atooth-to-tooth spacing (or ridge-to-ridge spacing) referred to as thepitch P. As shown, depth of engagement E is a measure of the level ofintermeshing of rolls 102 and 104 and is measured from tip of ridge 106to tip of tooth 110. The depth of engagement E, tooth height TH, andpitch P can be varied as desired depending on the properties ofprecursor webs 20, 21 and the desired characteristics of web 1. Forexample, in general, the greater the level of engagement E, the greaterthe necessary elongation or fiber-to-fiber mobility characteristics thefibers of portions of the precursor webs intended to form tufts mustpossess. Also, the greater the density of tufts 6 desired (tufts 6 perunit area of web 1), the smaller the pitch should be, and the smallerthe tooth length TL and tooth distance TD should be, as described below.

FIG. 7 shows one embodiment of a roll 104 having a plurality of teeth110 useful for making a web 1 from a nonwoven first precursor web 20having a basis weight of between about 60 gsm and 100 gsm, preferablyabout 80 gsm and a polyolefinic film (e.g., polyethylene orpolypropylene) second precursor web 21 having a density of about0.91-0.94 and a basis weight of about 20 gsm.

An enlarged view of teeth 110 is shown in FIG. 8. In this embodiment ofroll 104 teeth 110 have a uniform circumferential length dimension TLmeasured generally from the leading edge LE to the trailing edge TE atthe tooth tip 111 of about 1.25 mm and are uniformly spaced from oneanother circumferentially by a distance TD of about 1.5 mm. For making aterry-cloth web 1 from web 1 having a total basis weight in the range ofabout 60 to about 100 gsm, teeth 110 of roll 104 can have a length TLranging from about 0.5 mm to about 3 mm and a spacing TD from about 0.5mm to about 3 mm, a tooth height TH ranging from about 0.5 mm to about 5mm, and a pitch P between about 1 mm (0.040 inches) and about 5 mm(0.200 inches). Depth of engagement E can be from about 0.5 mm to about5 mm (up to a maximum equal to tooth height TH). Of course, E, P, TH, TDand TL can be varied independently of each other to achieve a desiredsize, spacing, and area density of tufts 6 (number of tufts 6 per unitarea of web 1).

As shown in FIG. 8, each tooth 110 has a tip 111, a leading edge LE anda trailing edge TE. The tooth tip 111 is elongated and has a generallylongitudinal orientation, corresponding to the longitudinal axes L oftufts 6 and discontinuities 16. It is believed that to get the tufted,looped tufts 6 of the web 1 that can be described as being terrycloth-like, the LE and TE should be very nearly orthogonal to the localperipheral surface 120 of roll 104. As well, the transition from the tip111 and LE or TE should be a sharp angle, such as a right angle, havinga sufficiently small radius of curvature such that teeth 110 pushthrough second precursor web 21 at the LE and TE. Without being bound bytheory, it is believed that having relatively sharply angled tiptransitions between the tip of tooth 110 and the LE and TE permits theteeth 110 to punch through precursor webs 20, 21 “cleanly”, that is,locally and distinctly, so that the first side 3 of the resulting web 1can be described as “tufted” rather than “deformed.” When so processed,the web 1 is not imparted with any particular elasticity, beyond whatthe precursor webs 20 and 21 may have possessed originally.

At higher line speeds, i.e., relatively higher rates of processing ofthe web through the nip of rotating rolls 102 and 104, like materialscan exhibit very different structures for tufts 6. The tuft 6 shown inFIG. 9 is similar in structure to the tuft shown in FIG. 2 but exhibitsa very different structure, a structure that appears to be typical ofspunbond nonwoven first precursor webs 20 processed to form tufts 6 atrelatively high speeds, i.e., at high strain rates. Typical of thisstructure is broken fibers between the proximal portion, i.e., base 7,of tufts 6 and the distal portion, i.e., the top 31, of tuft 6, and whatappears to be a “mat” 19 of fibers at the top of the tuft 6. Mat 19comprises and is supported at the top of tufts 6 by unbroken, loopedfibers 8, and also comprises portions of broken fibers 11 that are nolonger integral with first precursor web 20. That is, mat 19 comprisesfiber portions which were formerly integral with precursor web 20 butwhich are completely detached from precursor web 20 after processing atsufficiently high line speeds, e.g., 30 meters per minute line speed inthe process described with reference to FIG. 5.

Therefore, from the above description, it is understood that in oneembodiment web 1 can be described as being a laminate web formed byselective mechanical deformation of at least a first and secondprecursor webs, at least the first precursor web being a nonwoven web,the laminate web having a first side, the first side comprising thesecond precursor web and a plurality of discrete tufts, each of thediscrete tufts comprising fibers integral with but extending from thefirst precursor web and fibers neither integral with nor extending fromthe first precursor web.

Although it is believed that the distinct fiber orientation observed atthe distal portion of tufts 6, e.g., mat 19, is due primarily toprocessing rates, it is also believed to be affected by otherparameters, such as fiber type and basis weight of the precursor webs 20and 21 as well as processing temperatures that can affect the degree offiber-to-fiber bonding. Matting of fibers is believed to occur on theportion of tuft 6 associated during manufacturing with the tip of tooth110 of roll 104. It is believed that frictional engagement of the fibersat the tip of the teeth “lock” the fibers in place, thereby limitingfiber elongation and/or fiber mobility, two mechanisms believed topermit formation of tufts 6. Therefore, once locked, so to speak, inposition, fibers adjacent tooth 110 tip can be broken, and, due to therandom entanglement of the precursor web as well as possible coldwelding of fibers due to pressure and friction, the broken fibers 11become and remain lodged in mat 19 at the distal end 3 of tufts 6.

Precursor webs having relatively higher basis weights generally haverelatively more fiber 11 portions in mat 19. In one sense, it appears asif most of the fiber content of the precursor webs in the immediatevicinity of a tooth tip 110 during manufacture can be simply displacedin the Z-direction to the distal portion 3 of tufts 6, resulting in mat19. First precursor webs 20 comprising relatively low elongation fibers,or fibers with relatively low fiber-to-fiber mobility (e.g., relativelylimited capability for fiber reptation) appear to result in relativelyfew fibers becoming and remaining lodged in mat 19 at the distal end 3of tufts 6. Fiber-to-fiber mobility can be increased by reducing oreliminating the fiber-to-fiber bonds. Thermal bonds can be completelyeliminated (i.e., avoided by not bonding), or reduced in certainnonwoven webs to increase fiber-to-fiber mobility. Similarly,hydroentangled webs can be less entangled to increase fiber-to-fibermobility. For any precursor web 20, lubricating it prior to processingas disclosed herein can also increase fiber-to-fiber mobility. Forexample, a mineral oil lubricant can be applied to first precursor web20 prior to it entering the nip 116 of rolls 102 and 104. Additionally,a plasticizing agent, such as petrolatum, can be added to some syntheticfiber webs, such as polyethylene or a polyethylene and polypropyleneweb, to increase extensibility.

While not wishing to be bound by theory, it is believed that if thefibers of the first precursor web have a highly curvilinear shape, e.g.,curled fibers, the resultant tufts 6 will have more looped fibers 8 andless broken fibers 18 as compared to more linear fiber conformations. Itis believed that such fiber conformations have a lesser chance ofbridging between two adjacent teeth, and, as a result they are lessprone to be stretched beyond their breaking point, and thus have agreater chance of forming complete loop structures. Furthermore, suchcurvilinear-shaped fibers can be made by using eccentric bicomponentfibers, or side-by-side bicomponent fibers, such as bicomponent fibersconsisting of polyethylene and nylon.

It has been found that certain nonwoven webs, such as carded webscomprising staple-length fibers, when used as a precursor web producevery few looped fibers 8 in tufts 6, so that the tufts 6 produced inthese webs may not be described as comprising a plurality of looped,aligned fibers 8 as described above with respect to FIGS. 1-4. Instead,carded nonwoven webs can produce tufts 6 having few, if any, looped,aligned fibers 8, and many, if not all, non-aligned fibers and/or brokenfibers 18. It is believed that the non-alignment of fibers in tufts 6made from carded webs is due in part to the nature of the fiber contentof carded webs. Staple fibers are not “endless,” but, instead have apredetermined length on the order of about 15 mm to about 100 mm, and,more typically from about 40 mm to about 80 mm. Therefore, when a cardedweb is processed by the apparatus described with respect to FIG. 5, itis believed that there is a much greater likelihood that a loose fiberend will be in the vicinity of a tuft 6 and thus produce a non-loopedfiber end in tuft 6. Furthermore, often staple fibers do not have thesame elongation characteristics of spunbond or meltblown fibers, forexample. However, even if tufts 6 have no looped fibers, the fibroustufts can nevertheless provide a softness benefit and produce a webuseful for use in a disposable absorbent article.

Therefore, from the above description, it is understood that in oneembodiment web 1 can be described as being a laminate web formed byselective mechanical deformation of at least a first and secondprecursor webs, at least the first precursor web being a nonwoven web,the laminate web having a first side, the first side comprising thesecond precursor web and a plurality of discrete tufts, the tuftscomprising a plurality of fibers integral with but extending from saidfirst region.

In preferred embodiments precursor webs are nonwoven web in which thereare minimal fiber-to-fiber bonds. For example, the precursor web can bea nonwoven web having a pattern of discrete thermal point bonds, as iscommonly known in the art for nonwoven webs. In general, however, it isbelieved to be desirable to minimize the number of bond points andmaximize the spacing so as to allow for some fiber mobility anddislocation at during formation of tufts 6. In general, utilizing fibershaving relatively high diameters, and/or relatively high extension tobreak, and/or relatively moderate or high fiber mobility, results inbetter and more distinctly formed tufts 6.

Although web 1 is disclosed in preferred embodiments as a two layer webmade from two precursor webs, it is not necessary that it be limited totwo layers. For example, a three-layer or more laminate can be made fromthree or more precursor webs, as long as one of the precursor webs canextend out-of-plane to form tufts. In general, it is not necessary thatadhesive or other bonding means be utilized to make laminate web 1. Theconstituent layers of web 1 (e.g., precursor webs 20 and 21 and anyother layers) can be held in a face-to-face laminated relationship byvirtue of the “locking” effect of the tufts 6 that extend throughopenings 4 in second precursor web 21. In some embodiments it may bedesirable to use adhesives or thermal bonding or other bonding means,depending on the end use application of web 1. For example, a web 1comprising bicomponent fiber nonwoven webs can be through-air bondedafter formation of tufts 6 to provide for layer-to-layer adhesion forgreater peel strength and for increased tuft stability. Additionally, itmay be desirable to apply adhesive to a portion of one of the precursorwebs. For example, in some embodiments adhesive or thermal bondingbetween layers can be selectively applied to certain regions of web 1.In the case of adhesive application, for example, adhesive can beapplied in a continuous manner, such as by slot coating, or in adiscontinuous manner, such as by spraying, extruding, and the like.Discontinuous application of adhesive can be in the form of stripes,bands, droplets, and the like.

In a multilayer web 1 each precursor web can have different materialproperties, thereby providing web 1 with beneficial properties withrespect to use as a topsheet in a disposable absorbent article, asdescribed more fully below. For superior fluid handling, for example,first precursor web 20 can be comprised of relatively hydrophilicfibers. Second precursor web 21 can be polymer film, e.g., apolyethylene film or an apertured polyethylene film, and can behydrophobic or rendered hydrophobic. The tufts 6 of such a web couldform an upper layer, i.e., a body-contacting layer when used as atopsheet on a disposable absorbent article. Fluid deposited upon theupper, relatively hydrophilic tufts is quickly transported away from therelatively hydrophobic film to the portion of the first precursor webunderlying the second film precursor web layer. One reason for theobserved rapid fluid transport is the capillary structures formed by thegenerally aligned fibers 8, 18 of tufts 6. The fibers 8, 18 formdirectionally-aligned capillaries between adjacent fibers, and thecapillary action is enhanced by the general convergence of fibers nearproximal portion 7 of tufts 6.

In another embodiment, first precursor web 20 can be comprised ofrelatively hydrophilic fibers. Second precursor web 21 can be comprisedof fibers that are relatively hydrophobic or rendered hydrophobic (i.e.,exhibit a contact angle with water of greater than about 70 degrees).The tufts 6 of such a web could comprise fibers from both precursor websto form a relatively hydrophobic upper layer, i.e., a body-contactinglayer when used as a topsheet on a disposable absorbent article. Fluiddeposited upon the web 1 can have lateral entry contact into voids 10 toreach relatively hydrophilic fibers, however, and thereby be quicklytransported away to underlying components of the absorbent article. Onereason for the observed rapid fluid transport in either structure isbelieved to be the capillary structures formed by the generally alignedfibers 8, 18 of tufts 6. The fibers 8, 18 form directionally-alignedcapillaries between adjacent fibers, and the capillary action isenhanced by the general convergence of fibers near proximal portion 7 oftufts 6.

It is believed that the rapid fluid transport is further increased dueto the ability of fluid to enter the web 1 via the voids 10 defined bylooped tufts 6. This “lateral entry” capability and/or capillary action,and/or the hydrophilicity gradient afforded by the structure of web 1makes web 1 an ideal material for optimal fluid handling for disposableabsorbent articles. In particular, a multilayer web 1 can provide foreven greater improvement in fluid handling characteristics.

In one embodiment, web 1 comprises a nonwoven first precursor web 20comprising a spunbond nonwoven having a basis weight of about 80 gsm,and comprising polyethylene/polypropylene (sheath/core) bicomponentfibers having an average diameter of about 33 microns, and a secondprecursor web comprising a polyethylene film having a basis weight of 20gsm. In this embodiment, web 1 has about 24 tufts 6 per squarecentimeter, the tufts 6 having a plurality of looped, aligned fibers 8,each of which has an average fiber diameter of about 18 microns. A webof this type can be beneficially used as a topsheet for disposableabsorbent articles, as shown below with reference to FIG. 11. Forexample, such a web 1 is fluid impermeable except in the regions of thetufts 6 which can wick fluid from the first side 3 of web 1 to thesecond side 5.

In one embodiment, as depicted schematically in FIG. 10, two nonwovenprecursor webs can be used, each precursor web having sufficient fibermobility or elongation such that tufts 6 comprise fibers from eachprecursor web. In a most preferred embodiment for use as a topsheet in asanitary napkin, web 1 can have a relatively hydrophilic first precursorweb 20 and a relatively hydrophobic second precursor web 21, such thatfibers from the relatively hydrophobic second precursor web 21 extend inthe most outwardly extending portions of tufts 6. That is, at the distalportion 31 of tufts 6 there are hydrophobic looped fibers 8 that canform a significant hydrophobic “cap” on the distal portion of the tufts6. This hydrophobic cap can have significant benefits when web 1 is usedas a topsheet in a sanitary napkin. By presenting a substantially fullyhydrophobic top surface, i.e., side 3, to the wearer's skin, thetopsheet promotes dryness on the skin. However, by presenting lateralentry to underlying hydrophilic fibers 8 in tufts 6 fluid can be quicklywicked through web 1 to underlying components of the sanitary napkin,such as an absorbent core, for example.

FIG. 11 shows in partial cut away plan view a sanitary napkin having asone of its components a web 1 of the present invention. In general,sanitary napkin 200 comprises a backsheet 202, a topsheet 206 and anabsorbent core 204 disposed between the topsheet 206 and backsheet 202which can be joined about a the periphery 210. Sanitary napkin 1 canhave side extensions, commonly referred to as “wings” 208 designed towrap the sides of the crotch region of the panties of the user ofsanitary napkin 1. Sanitary napkins, including topsheets for use as thebody facing surface thereof, are well known in the art and need nodetailed description of various alternative and optional designs.However, it is noted that web 1 can be used as, or as a component of,one or more of a backsheet, core material, topsheet, secondary topsheet,or wing material.

Web 1 is especially useful as a topsheet 206 of sanitary napkin 200. Web1 as described with respect to FIG. 10 is particularly beneficial as atopsheet 206 for sanitary napkins due to the combination of excellentfluid gush acquisition and distribution to an underlying absorbent core204, and excellent prevention of rewet to the body-facing surface oftopsheet 206 when in use. As described above, a topsheet 206 comprisinga web of the present invention made by using a relatively hydrophilicnonwoven first precursor web 20 and a relatively hydrophobic secondprecursor web 21 provides for a topsheet 206, that when viewed in planview as in FIG. 11 presents a substantially hydrophobic body-facingsurface. Therefore, in one embodiment, a web 1 useful for a topsheet 206can be described as a tufted laminate web having two sides, wherein oneside projects a substantially hydrophilic surface and the other sideprojects a substantially hydrophobic surface.

The topsheet 206 can comprise two layers, i.e., one layer correspondingto each precursor web, and the first precursor web could be consideredto be a secondary topsheet. But since the two webs are joined into alaminate composite, they are referred to herein as a topsheet 206. Thebasis weights of the precursor webs can be varied due to cost andbenefit considerations. In general, a web 1 having a total basis weightof between about 20 gsm and 100 gsm is desirable for use as a topsheet206 in a disposable absorbent article, such as a sanitary napkin. Secondprecursor web 21 can be a nonwoven web or a polymer film web. When madeas a hydrophilic/hydrophobic (one web with respect to the other)nonwoven/film laminate, web 1 has been found to combine the softness andfluid capillarity of fiber tufts with the rewet prevention of a fluidimpermeable polymer film. Likewise, when made as ahydrophilic/hydrophobic (one web with respect to the other)nonwoven/nonwoven laminate, web 1 has also been found to combineconsumer-acceptable softness with excellent gush fluid acquisition andrewet properties.

It is well known in the sanitary napkin field, as illustrated by Table 1below, and illustrated on the graph of FIG. 16, that there is a tradeoffbetween improving dryness (i.e., minimizing rewet) and improving gushacquisition rates of menses and other body fluids. That is, in generalfor known topsheets comprising nonwoven materials, improved dryness canbe obtained at the expense of gush acquisition rate. This is believed tobe due to the competing fluid handling properties of the nonwoven web.For example, higher density nonwoven webs can improve rewet propertiesat the expense of gush acquisition rates. Likewise, high surface energywebs can improve gush acquisition rates at the expense of rewetproperties. Unexpectedly, with the web of the present invention, theseotherwise competing properties are decoupled. For example, for webshaving similar capillarity characteristics, increasing the dryness(i.e., reducing rewet) on a topsheet requires that the topsheet berelatively hydrophobic, such that fluid, including menses (although itis recognized that menses has different fluid properties than water)does not wet the surface of the fibers. However, this lack ofwettability lowers the gush acquisition rates of fluid into or throughthe topsheet. Of course, increasing the wettability of the nonwovenfibers to increase the gush acquisition rate has the correspondingeffect of increasing the rewet values of the topsheet.

Therefore, when rewet and gush acquisition rate are graphed onorthogonal axes, the data show a very well known and predictable trendshowing that as dryness improves, gush acquisition rates decrease. Byway of example, the data in Table 1, which is graphed in FIG. 16, wasproduced using artificial menstrual fluid (AMF) and a test methodcomparable to the Gush Acquisition Rate and Rewet test method describedin the Test Method section below. As shown, current market products fallwithin a zone generally corresponding to a diagonally extended zonegenerally from the top left to the bottom right of the graph, asdepicted in FIG. 17. However, surprisingly, by use of a web 1 of thepresent invention as a topsheet 206, some sanitary napkins of thepresent invention were found to exhibit both acquisition rates and rewetvalues that lie well above such a diagonal zone, these sanitary napkinsshowing a marked increase in both dryness and gush acquisition rate.TABLE 1 AMF Testing of Gush Acquisition and Rewet First Gush SamplePrecursor Second Precursor Acquisiton Rate Rewet No. Description Web Web(ml/sec) (mg) 1 KOTEX ® N/A N/A 0.33 110 Quick Pores 2 NATURELLA ® N/AN/A 0.30 175 3 STAYFREE ® N/A N/A 1.07 280 4 KOTEX N/A N/A 0.59 138LeakLock 5 Web 1 over PP/Rayon 25 gsm Bico PE/PP 0.30 147 ALWAYS ® MaxiRegular Core 6 Web 1 over 30 gsm 25 gsm Bico PE/PP 1.35 484 ALWAYS ®hydrophilic Maxi Regular BiCo PE/PP Core 7 Web 1 over 30 gsm 25 gsm PP1.64 550 ALWAYS ® hydrophilic Maxi Regular BiCo PE/PP Core 8 Web 1 over30 gsm 25 gsm PP 0.91 369 ALWAYS ® hydrophilic Maxi Regular BiCo PE/PPCore 9 Web 1 over 45 gsm 25 gsm Bico PP/PE 1.54 50 ALWAYS ® 80%/20% 30Maxi Regular denier Core PET/Co-PET (4DG) 10 Web 1 over 46 gsm 25 gsmBico PE/PP 1.04 55 ALWAYS ® 80%/20% 6 Maxi Regular denier CorePET/Co-PET (Round) 11 Web 1 over 46 gsm 25 gsm Bico PE/PP 0.51 89ALWAYS ® 50%/50% 6 Maxi Regular denier Core PET/Co-PET (Round) 12 Web 1over 46 gsm 25 gsm Bico PE/PP 0.36 104 ALWAYS ® 20%/80% 6 Maxi Regulardenier Core PET/Co-PET (Round)

Samples 1-4 were all purchased current market products. All values areaverages with n=10.

The PP/Rayon nonwovens were a carded blend of 70% 2.2 denierpolypropylene(PP)/30% 5 denier rayon, available from PGI Nonwovens underthe designation 164-253-6.

The 25 gsm Bico PE/PP nonwovens were relatively hydrophobic spunbondbicomponent PE/PP (sheath/core) fiber nonwoven webs obtained from BBANonwovens, Washougal, Wash. under the designation 074YLCO09U.

The hydrophilic BiCo PE/PP was a 30 gsm relatively hydrophobic spunbondbicomponent PE/PP (sheath/core) fiber nonwoven web obtained from BBANonwovens, Washougal, Wash. under the designation 088YLCO09U.

The “4DG” fibers were surfactant treated PET, crimped, 2-inch cut lengthfibers having a cross-section exhibiting channels that can act as fluidcapillaries, obtained from Fiber Innovation Technologies, Johnson City,Tenn. Such fibers are sometimes referred to as capillary channel fibers.

The “round” fibers were surfactant treated PET, crimped, 2-inch cutlength fibers having a round cross-sectional shape, obtained fromWellman, Inc., Charlotte, N.C. under the designation Type 204.

The “% PET fibers” refers to the percentage of PET fibers in the firstprecursor web. In all Samples 3-14, these fibers are blended withrelatively hydrophilic 6 denier co-PET crimped, 2-inch cut lengthbicomponent binder fibers (higher melting PET core/low melting point PETsheath) obtained from Kanematsu USA, Gastonia, N.C. under thedesignation LM651. All percentages refer to weight percent.

Particularly in the Samples using relatively stiff fibers, such as PETfibers, the data showed results heretofore unobtainable, both improvedgush acquisition rates, and improved dryness (lowered rewet). Such asurprising finding—both dryness and gush acquisition rate exhibiting asignificant directional improvement with the use of the presentinvention-prompted further testing, this time using a more readilyduplicated fluid, namely Paper Industry Fluid, commonly referred to asPIF. PIF is a well-known fluid used for simulating relatively highviscosity fluids such as menses. Additional testing using PWF wasperformed according to the Gush Acquisition Rate and Rewet methoddescribed below. The results of the PIF testing are shown in Tables 2and 3. Table 2 shows the results of testing the web of the presentinvention in place of the topsheets on two well-known existing marketproducts. Table 3 shows the results of testing the web of the presentinvention over current airfelt core of the type used in Always® MaxiRegular sanitary napkins, available from The Procter & Gamble Co.,Cincinnati, Ohio.

In general it is noted that certain samples tested with AMF wereduplicated using PIF and the results were seen to correlate in aproportional manner, with the PIF giving more modest improvements forboth rewet and acquisition rate. That is, for a given sample, testingwith PWF shows proportionally poorer values for both dryness and gushacquisition rate than does testing with AMF. However, even with the useof PIF, as shown in Tables 2 and 3, the tested values continue to bebetter in both gush acquisition rate and rewet than existing products.Therefore, tested values using AMF, menses, and/or consumer experienceare each expected to be exhibit better results than those shown in theTables below. TABLE 2 PIF Testing Using Current Market Products GushGush Acquisition Acquisition Rate Rewet Sample Rate Improvement RewetImprovement No. Product Topsheet (ml/sec) (%) (mg) (%) 1 KOTEX ® As 0.39409 LeakLock purchased Web of the 0.67 41.8 280 46.1 present invention 2STAYFREE ® As 0.46 94 4- purchased Wall Web of the 0.65 28.7 49 91.8present invention

The Samples listed in Table 2 were store-purchased and tested accordingto the Test Method detailed below. The values shown for Gush AcquisitionRate and Rewet are averages of 10 tests for each value. In the “aspurchased” condition, each Sample was tested without modification of theproduct. As shown in Table 2, for each product additional samples weretested after replacement of the existing topsheet with a web of thepresent invention as described below. This was accomplished by carefullyremoving the existing topsheet (and, if necessary any secondarytopsheets) so as to not disturb the underlying absorbent core, andthereafter, placing a topsheet of the present invention over the core ina manner to simulate a machine made product. The webs of the presentinvention used in the testing shown in Table 2 had the followingcomposition:

First precursor web: 45 gsm carded nonwoven web comprising a blend of80% relatively hydrophilic 30 denier crimped, shaped, 2-inch cut lengthPET fibers obtained from Fiber Innovation Technologies, Johnson City,Tenn., under the designation 4DG, and 20% relatively hydrophilic 6denier co-PET crimped, 2-inch cut length bicomponent binder fibers(higher melting PET core/low melting point PET sheath) obtained fromKanematsu USA, Gastonia, N.C. under the designation LM651.

Second precursor web: 30 gsm relatively hydrophobic spunbond bicomponentPE/PP (sheath/core) fiber nonwoven web obtained from BBA Nonwovens,Washougal, Wash. under the designation 088YLCO09U.

The first and second precursor webs were processed by the methoddescribed in the specification above using the intermeshing rollsdescribed above. Specifically, for each sample, the toothed rolls had apitch P of 1.5 mm, an engagement E of 3.4 mm, and a uniform tooth heightTH of 3.7 mm. The intermeshing rolls were rotated so as to process thewebs at an approximate rate of about 3 m/min.

As shown by the data in Table 2, current market products exhibit asignificant improvement in both rewet and acquisition rate by the use ofa topsheet comprising a web of the present invention. The measured fluidhandling parameters have a direct impact on consumer-desired properties.Therefore, by using topsheets comprising a web of the present invention,current market products can be significantly improved to deliverimportant consumer benefits.

Additional webs 1 of the present invention were produced with the samesecond precursor web as those used in Samples 1 and 2 of Table 2, butwith varying first precursor web and fiber characteristics, as shown inTable 4. These webs were tested by the Acquisition Rate and Rewet testmethods shown below to give the data shown in Table 3. For the datashown in Table 3, each topsheet was tested over airfelt absorbent coresremoved from store-bought ALWAYS® Maxi Regular sanitary napkins. TABLE 3PIF Testing of Present Invention on ALWAYS ® Absorbent Cores FirstPrecursor Web Fiber PET PET Web Basis Acquisition Sample Size FiberFibers Weight Rate Rewet No. (denier) Shape (%) (gsm) (ml/sec) (mg) 3 64DG 80 45 0.51 17.5 4 14 4DG 80 45 0.64 33 5 30 4DG 80 45 0.44 25.7 6 6Round 80 45 0.11 23 7 6 Trilobal 80 45 0.47 22 8 6 4DG 80 45 0.51 17.5 96 Round 80 46 0.4 19.5 10 6 Round 80 49 0.54 22 11 6 Round 80 66 0.8127.6 12 30 4DG 20 45 0.015 36.2 13 30 4DG 50 45 0.33 25.3 14 30 4DG 8045 0.44 25.7

Each of the Samples shown in Table 3 were processed with the firstprecursor web 20 indicated by the method described above using theintermeshing rolls described above. ch sample, the toothed rolls had apitch P of 1.5 mm, an engagement E of 3.4 mm, and a uniform tooth heightTH of 3.7 mm. The intermeshing rolls were rotated so as to process thewebs at an approximate rate of about 3 m/min.

The “trilobal” fibers were surfactant treated PET, crimped, 2-inch cutlength fibers having a triobal cross-sectional shape obtained from FiberInnovation Technologies, Johnson City, Tenn.

The “4DG” fibers were surfactant treated PET, crimped, 2-inch cut lengthfibers having a cross-section exhibiting channels that can act as fluidcapillaries, obtained from Fiber Innovation Technologies, Johnson City,Tenn. Such fibers are sometimes referred to as capillary channel fibers.

The “round” fibers were surfactant treated PET, crimped, 2-inch cutlength fibers having a round cross-sectional shape, obtained fromWellman, Inc., Charlotte, N.C. under the designation Type 204.

The “% PET fibers” refers to the percentage of PET fibers in the firstprecursor web. In all Samples 3-14, these fibers are blended withrelatively hydrophilic 6 denier co-PET crimped, 2-inch cut lengthbicomponent binder fibers (higher melting PET core/low melting point PETsheath) obtained from Kanematsu USA, Gastonia, N.C. under thedesignation LM65 1. All percentages refer to weight percent.

The web basis weight refers to the basis weight of the first precursorweb only.

As can be seen from the Gush Acquisition Rate and Rewet results in Table3, the web of the present invention provides for superior gushacquisition rates and dryness values compared to other, known topsheets(see, e.g., “as purchased” values in Table 2). On a graph similar tothat shown in FIG. 16, this data would be plotted in the upper rightquadrant, a clear departure from current, known webs useful as topsheetson disposable absorbent articles.

In particular, from the results in Tables 2 and 3, it can be seen that aweb of the present invention, when used as a topsheet in a disposableabsorbent article, delivers both a gush acquisition rate of at least0.11 ml/sec, and a rewet value much less than about 94 mg. In oneembodiment a superior disposable absorbent article, such as a sanitarynapkin, can be provided by utilizing a topsheet comprising a web of thepresent invention wherein the article exhibits a rewet value of lessthan about 75 mg and a fluid acquisition rate of at least about 0.5ml/sec. In another embodiment, the article can exhibit a rewet value ofless than about 25 mg and a fluid acquisition rate of at least about 1.0ml/sec.

Without being bound by theory, it is believed that the superior fluidhandling results can be attributed to at least two factors: (1) thehydrophilicity/hydrophobicity differences between the first and secondprecursor webs, respectively; and, (2) the presence of relatively stifffibers in tufts 6 that can aid in retaining caliper under load. That is,relatively stiff fibers oriented generally in the Z-direction (e.g., asshown in FIG. 3) act as flexible columns of support to provide effectivestand-off of the web and resistance to compression forces. In oneembodiment it is believed to be most beneficial to have relatively stifffibers in the first precursor web, and relatively soft fibers in thesecond precursor web, such that upon forming of tufts comprising bothfibers from both webs (e.g., as shown in FIG. 10), the relatively softfibers are at the distal-most portion of the tufts, and therefore, thesubstantially all the fibers that contact the skin of a wearer can berelatively soft fibers.

FIG. 12 shows in partial cut away perspective view a catamenial tampon300 having as one of its components a web 1 of the present invention. Ingeneral, tampon 300 comprises a compressed absorbent core 302 and afluid permeable cover wrap 304 that covers absorbent core 302. Coverwrap 304 may extend beyond one end of absorbent core 302 to form a skirtportion 306. A removal means, such as string 308 can be provided tofacilitate removal of the tampon after use. Tampons, including coverwraps for use as the body contacting surface thereof, are well known inthe art and need no detailed description of various alternative andoptional designs. However, it is noted that web 1 can be used as, or asa component of, one or more of a cover wrap, absorbent core material, orremoval means material.

Table 4 below shows representative examples of other structures of webs1 useful for components in articles of present invention, along withdimensions relative to the apparatus 100 used in the process to makethem, as disclosed hereinabove. A brief description of each Samplelisted follows Table 4. TABLE 4 Examples of Apparatus DimensionalParameters and Web Dimensions Avg. Fiber Avg. Tooth Diameter Fiber PitchEngagement Height Loop of Diameter (P) (E) (TH) height Precursor of LoopSample Precursor Precursor Precursor <mm> <mm> <mm> (h) Web 1 Fiber No.Web 1 Web 2 Web 3 (inches) (inches) (inches) (mm) (μm) (μm) 1 Carded PETLDPE N/A <1.5> <3.4> <3.7> 1.59 20 18 nonwoven Film (0.060) (0.135)(0.145) web 2 Spunbond 30 lb Kraft N/A <1.5> <3.4> <3.7> 1.38 24 13PE/PP paper (0.060) (0.135) (0.145) core/sheath nonwoven web 3Spunbonded Airlaid Spunbonded <1.5> <3.4> <3.7> 1.83 34 28 PP PET PP(0.060) (0.135) (0.145) nonwoven nonwoven nonwoven web web web

FIG. 13 is a photomicrograph of Sample 1. The first precursor web ofSample 1 was a carded PET nonwoven web having a basis weight of 145grams per square meter (gsm) that was hand carded from 38 mm (1.5 inch)staple length polyester/co-polyester trilobal-shaped fibers, type F30A,from FIT (Fiber Innovation Technology) Inc., Johnson City, Tenn. Thesecond precursor web of Sample 1 was a low density polyethylene (LDPE)film having a caliper of 0.1 mm (0.004 inch) made by Huntsman FilmProducts Co., Carrolton Ohio., designated as X420. Sample 1 was producedon an apparatus as described above with respect to FIG. 5 at a linespeed of approximately 3 meters per minute (10 feet per minute). Asshown in FIG. 13, flap 7 extends significantly out of the plane of thesecond precursor web (i.e., the film layer) and covers approximatelyhalf of the tuft 6. As noted above, this can be desirable where a morestiff, resilient tuft 6 is desired.

FIG. 15 is a photomicrograph of Sample 2. The first precursor web ofSample 2 is a spunbond PE/PP 50/50 core/sheath nonwoven having a basisweight of 30 gsm and was made by BBA, Simpsonville S.C. The secondprecursor web of Sample 3 was brown 100% recycled 30 lb Kraft packagingpaper available from any source of Kraft paper, e.g., Uline ShippingSupplies, Waukegan, Ill. Sample 2 was produced on an apparatus asdescribed above with respect to FIG. 5 at a line speed of approximately3 meters per minute (10 feet per minute). As shown in FIG. 15, a secondprecursor web of Kraft paper can result in openings 4 and flaps 7 thatresemble a volcano-shaped opening.

FIG. 16 is a photomicrograph of Sample 3, which comprises threeprecursor webs. The first and third precursor webs of Sample 3 were aspunbond polypropylene nonwoven having a basis weight of 13.5 gsm,designated NW30 from First Quality Nonwovens, Haxleton, Pa. The firstand third precursor webs were the outer layers, sandwiching the secondprecursor web which was a loosely bonded airlaid nonwoven web made from44 mm (1.75 inch) long staple fibers comprising polyester fibers andPE/PP 50/50 core/sheath nonwoven bicomponent binder fibers in an 80/20fiber ratio by weight, respectively. The polyester fibers were Type 1311fibers and the PE/PP fibers were Type 851607 fibers, both fibers beingavailable from FIT (Fiber Innovation Technology) Inc., Johnson City,Tenn. Sample 4 was produced on an apparatus as described above withrespect to FIG. 5 at a line speed of approximately 30 meters per minute(100 feet per minute). As shown in FIG. 16, in some embodiments of web 1there may be no flaps 7 to speak of, but only a slight disruption ofsecond precursor web around the opening through which tufts 6 extend.The tufts 6 shown in FIG. 16 can be seen to comprise two fiber types.Fibers from both the middle, sandwiched airlaid web, and one of theouter layers contribute to the tuft 6.

As can be understood from the above description of webs 1 and apparatus100 of the present invention, many various structures of webs 1 can bemade without departing from the scope of the present invention asclaimed in the appended claims. For example, webs 1 can be coated ortreated with lotions, medicaments, cleaning fluids, anti-bacterialsolutions, emulsions, fragrances, surfactants. In particular, relativelyhydrophobic lotion having a hydrophilic/lipophilic balance (HLB) of lessthan or equal to 7. The lotion can be petrolatum-based and can compriseskin treatment agents and other ingredients as disclosedcommonly-assigned U.S. patent application Ser. No. 10/444,241 (Docketnumber 8725R2), which is hereby incorporated herein by reference. Web 1can be treated such that only the distal ends of the tufts 6 have lotionapplied thereto, such that the web 1 can be described as a web having afirst side and a second side, wherein tufts at least partially originatein the second side and extending to a distal body-facing portion, thedistal body-facing portion being relatively hydrophobic with respect tothe second side.

Apparatus 100 can be configured to only form tufts 6 on a portion of theweb 1, or to form varying sizes or area densities of tufts 6.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

TEST METHOD

Preparation of Paper Industry Fluid (PIF)

Reagents: *Carboxymethylcellulose (CMC), #C-5678 15 g *Glycerin #G-789380 g Sodium Chloride, A.C.S. reagent grade 10 g Sodium Bicarbonate,A.C.S. reagent grade 4 g Distilled Water 1000 mL *[Optional] IndigoCarmine dye, such as Aldrich #13,116-4 0.01%*Note: available from Sigma Chemical Co. USA (314)771-5750 orSigma-Aldrich, Germany 49-7329-970.Procedure:

-   -   Step 1: Add 80.0 (+/−0.05 g) of glycerin to a beaker. Set to one        side.    -   Step 2: Weigh 15.0 (+/−0.05 g) of CMC.    -   Step 3 Slowly add the pre-weighed CMC to the beaker containing        the glycerin while continuously stirring using a glass stirring        rod. Mix to a slurry (CMC particles suspended in glycerin).    -   Step 4: Add 300 mL (+/−5 mL ) of distilled water the beaker and        continue to mix briefly with the stirring rod. NOTE: Remove any        CMC/glycerin residue from the stirring rod by rinsing it off        with more distilled water into the beaker using only a small        quantity of distilled water (20-50 mL).    -   Step 5: Weigh 10.0 (+/−0.01 g) of sodium chloride. Set to one        side.    -   Step 6: Weigh 4.0 (+/−0.01 g) of sodium bicarbonate. Set to one        side.    -   Step 7: Place a magnetic stir bar into the beaker of glycerin        and place on top of a magnetic stir plate. Turn on the stir        plate to continuously mix the solution.    -   Step 8: Add all other reagents, and then add more distilled        water to the suspension to bring the volume up to approximately        850 mL.    -   Step 9: Continue to stir for 20 minutes. Solution should be        clear.    -   Step 10: Immediately after stirring for 20 minutes, remove the        magnetic stir bar and transfer the solution into a volumetric        flask. Rinse any remaining residue from the beaker into the        solution in the volumetric flask using small quantities of water        each time (20-50 mL). Continue to add more distilled water to        bring the final volume up to the 1000 mL mark on the flask. The        bottom of the meniscus should be level with the etched mark at        eye level.    -   Step 11: *[Optional] Add 0.01% Indigo Carmine dye.    -   Step 12: Place the magnetic stir bar back into the solution in        the volumetric flask. Continue to mix for an additional 10-15        minutes.    -   Step 13: Using a viscometer check the viscosity of the PIF test        fluid at 22 +/−0.5 degrees C using a water bath and a        thermometer to monitor and control the temperature of the PIF        test fluid for the viscosity reading. Follow the viscometer        manufacturer's operating instructions for the specific        viscometer to be used. Select the appropriate spindle and run at        30 RPM    -   Note: The density of PIF is 1.03.    -   Viacosity Target:        -   Centipoise (cP): Viscosity Range 10-12 cP at 22 degrees C.        -   Centistokes (cStk): Viscosity Range 9.70-11.64 cStk at 22            degrees C.    -   Notes: If viscosity is below the target add more CMC. If        viscosity is over the target, add more distilled water.        -   Viscosity of PIF can change with time. Therefore, viscosity            measurements must be made daily or prior to use when storing            PIF for more than 24 hours.        -   Discard any unused, or out-of-spec PIF in accord with            local/regional safe disposal procedures.        -   PIF has a shelf life of seven days at room temperature and            14 days refrigerated.            Gush Acquisition and Rewet Test    -   Step 1: Condition Samples to be tested by equilibrating for 2        hours at a temperature of 69-77 degrees F. and a humidity of        46-54% prior to testing.    -   Step 2: Samples are to be tested in an environment with a        temperature of 69-77 degrees F and a humidity of 46-54%.    -   Step 3 Place a 4 inch square block with a 1 inch by 0.6 inch        opening over the center of the Sample to be tested. Add        sufficient weight to the block to achieve a 0.25 psi pressure.    -   Step 4: Add four 1 mL aliquots of PIF through the opening to the        Sample and wait for the each aliquot to absorb into the Sample        before adding the next.    -   Step 5: After the last of the four aliquots of PIF is absorbed        into the Sample, wait five minutes and add 3 mL of PIF at a rate        of approximately 1 mL/sec to simulate a gush of menses. Time the        interval between the first drop of PIF until no PIF is visible        on the top surface of the Sample. This time interval is used to        calculate and report the gush acquisition rate in ml/sec.    -   Step 6: Immediately remove the 0.25 psi block and wait 30        seconds,. at which time place a stack of seven 5-inch square        pre-weighed Ahlstrom Filtration Co. # 632 filter papers (the        filter papers also having been pre-conditioned for 2 hours at a        temperature of 69-77 degrees F. and a humidity of 46-54% prior        to testing) over the central portion of the Sample that received        the fluid gush.    -   Step 7: Place a weight sized to be 0.77 psi on the filter papers        for 15 seconds.    -   Step 8: Remove the 0.77 psi weight and immediately weight the        filter papers.    -   Step 9: Calculate the Rewet in grams by subtracting the weight        of the filter paper before being placed under the 0.77 psi        weight for 15 seconds from the weight after.    -   Steps 1-9 are repeated for at least 10 specimens for each        Sample, and the average of the 10 specimens is reported.

1. An absorbent article comprising a topsheet, a backsheet, and anabsorbent core disposed between the topsheet and the backsheet, thetopsheet having a first side and a second side, the first side being abody-facing side, said topsheet defining a CD-MD plane and comprising afibrous nonwoven web and tufts, said tufts comprising fibers of saidfibrous nonwoven web, said topsheet further comprising first, second andthird zones, each said zone being characterized in a Z-direction by thezone fiber orientation, wherein said first and third zones are displacedrelative to each other and each comprise fibers having portionsorientated substantially parallel to said CD-MD plane of said topsheet,and said second zone is intermediate and adjacent to said first andthird zones, said second zone comprising substantially reoriented fibersthat are substantially vertically oriented with respect to said CD-MDplane of said topsheet.
 2. The absorbent article of claim 1, whereinsaid topsheet is a laminate of a nonwoven and a film, wherein said tuftsextend through said film.
 3. The absorbent article of claim 2, whereinsaid nonwoven web is relatively hydrophilic with respect to said film.4. The absorbent article of claim 1, wherein said tufts extend out ofsaid fibrous nonwoven web on said first, body-facing side of saidtopsheet.
 5. The absorbent article of claim 1, wherein said tufts aresufficiently closely spaced so as to cover said first, body-facing sideof said topsheet.
 6. An absorbent article comprising a topsheet, asecondary topsheet a backsheet, and an absorbent core disposed betweenthe secondary topsheet and the backsheet, the secondary topsheet havinga first side and a second side, the first side being a body-facing side,said secondary topsheet defining a CD-MD plane and comprising a fibrousnonwoven web and tufts, said tufts comprising fibers of said fibrousnonwoven web, said secondary topsheet further comprising first, secondand third zones, each said zone being characterized in a Z-direction bythe zone fiber orientation, wherein said first and third zones aredisplaced relative to each other and each comprise fibers havingportions orientated substantially parallel to said CD-MD plane of saidsecondary topsheet, and said second zone is intermediate and adjacent tosaid first and third zones, said second zone comprising substantiallyreoriented fibers that are substantially vertically oriented withrespect to said CD-MD plane of said secondary topsheet.
 7. The absorbentarticle of claim 6, wherein said secondary topsheet is a laminate of anonwoven and a film, wherein said tufts extend through said film.
 9. Theabsorbent article of claim 6, wherein said nonwoven web is relativelyhydrophilic with respect to said film.
 10. The absorbent article ofclaim 6, wherein said tufts extend out of said fibrous nonwoven web onsaid first, body-facing side of said secondary topsheet.
 11. Theabsorbent article of claim 6, wherein said tufts are sufficientlyclosely spaced so as to cover said first, body-facing side of saidtopsheet.
 12. The absorbent article of claim 6, wherein said tuftsextend out of said fibrous nonwoven web on said second side of saidsecondary topsheet.
 13. An absorbent article comprising a topsheet, abacksheet, and an absorbent core disposed between the topsheet and thebacksheet, the topsheet having a first side and a second side, the firstside being a body-facing side and the second side being in fluidcommunication with the absorbent core, said topsheet defining a CD-MDplane and comprising a fibrous nonwoven web and tufts, said tuftscomprising fibers of said fibrous nonwoven web, said topsheet furthercomprising first, second and third zones, each said zone beingcharacterized in a Z-direction by the zone fiber orientation, whereinsaid first and third zones are displaced relative to each other and eachcomprise fibers having portions orientated substantially parallel tosaid CD-MD plane of said topsheet, and said second zone is intermediateand adjacent to said first and third zones, said second zone comprisingsubstantially reoriented fibers that are substantially verticallyoriented with respect to said CD-MD plane of said topsheet, said tuftsat least partially originating in said second side and extending to adistal body-facing portion, the distal body-facing portion beingrelatively hydrophobic with respect to the second side.
 14. Theabsorbent article of claim 13 wherein said distal body-facing portion ofsaid tufts is rendered hydrophobic by a lotion composition disposedthereon.
 15. The absorbent article of claim 14 wherein said lotioncomposition comprises a hydrophilic/lipophilic balance (HLB) of lessthan or equal to
 7. 16. The absorbent article of claim 14 wherein saidlotion composition comprises petrolatum.